So I decided to order and upper without bcg and CH. But added them separately. the bcg and ch shipped first. About a week later the upper arrived. About in the time i figured. a couple of weeks or there bouts.

Once in hand I attempted to put the three components together but to my surprise the ch would not fit into the cutouts in the top of the receiver, huh. So I took another ch from another rifle I have and it fit no problem. Actually the new ch fig into my other upper, wth?
So I went ahead and put the upper onto my lower with my used ch and the new bcg. The front pin fought me a bit but was able to get it in. The rear pin started but nope it was enough mis-aligned that it did not want to go I did not want to force it. Now I am at wtf?
So I take the upper to my other rifles lower. It was tight but was able to get both pins in. After some lube and exercising it seemed ok, albeit tight. So I go back to the other lower which is the one I intend on using it with. And it will go now but is pretty tight. Think it will loosen a bit with use.

I am befuttled about the new ch not fitting the new upper.

Would like to hear some thoughts on the ordeal. Thanks guys and gals.

Sounds like you have some tolerance stacking issues going on. Something on the top end of spec and something else on the low end leading to some fits and clearances issues.

call PSA. I have never had a problem with them, but I understand they will take care of issues.

Hit up Josiah at Palmetto st armory customer service. He’s usually pretty good.

If you got the pins to finally go through, I wouldn’t worry about it unless you’re worried about it damaging the retainer pin holes on the lower … tight is good, to a point. I agree that there is some minor issues with tolerance.

Since my original post I bought a used Rock River complete lower. I ordered a PSA complete upper to go with it. The hinge pin fits just fine, but the take down pin would not go into the upper. I did some web cruising and decided to slightly enlarge the hole in the upper. So far the pin goes 1/2way through the upper hole. I have another complete RRA, and the fit on the take down pin is tighter than necessary.

Maybe put a tiny bit of good grease on the pin if you plan to keep. I think PSA has some issues. Such as the CH not fitting in the uppers cutouts on mine. They need to do better. This is pretty basic quality control that is lacking. Disappointing. I am thinking of returning mine and using the funds toward a LaRue upper now.